Half shaft with double stub end

Abstract

The claimed invention is directed to a novel composite half shaft. More specifically, the claimed invention provides for the integration of a continuous velocity joint within the hollow tubular portion of the axle shaft, which permits for a longer lightweight composite hollow shaft. The use of the lightweight material over additional length results in an overall weight reduction. Additional benefits include reduced unsprung weight in vehicles, improved mileage for gas powered vehicles and increased range for electric vehicles. The use of composite materials in place of a solid or hollow metal axle bar results in improved noise, vibration and harshness (“NVH”) characteristics over conventional half shafts..

What is claimed is: 
     
         1 . A composite half shaft comprising:
 a hollow tubular composite axle having an inner wall;   a constant velocity joint comprising a bearing, the bearing comprising an inner race and an outer race, the exterior of the outer race being secured to the inner wall of the hollow tubular composite axle; and   a double stub end having at least a first end secured to the inner race of the bearing and a second end protruding from the hollow tubular composite axle.   
     
     
         2 . The composite half shaft of  claim 1  further comprising a flexible rubber boot, the rubber boot being attached at a first end around the tubular composite axle or constant velocity joint and at the second end around the double stub end. 
     
     
         3 . The composite half shaft of  claim 1  wherein the constant velocity joint is press fit into the inner wall of the hollow tubular composite axle. 
     
     
         4 . The composite half shaft of  claim 1  wherein the constant velocity joint is secured to the inner wall of the hollow tubular composite axle with an adhesive. 
     
     
         5 . The composite half shaft of  claim 1  wherein the constant velocity joint is situated almost entirely within the inner wall of the hollow tubular composite axle. 
     
     
         6 . The composite half shaft of  claim 1  wherein the constant velocity joint is a tripod joint. 
     
     
         7 . A composite half shaft assembly comprising:
 a hollow tubular composite axle having an inner wall and an outer wall and having a power input end and a power output end;   a power input constant velocity joint comprising a power input bearing, the power input bearing comprising an inner race and an outer race, the exterior of the outer race being secured to the inner wall of the hollow tubular composite axle at the power input end;   a power input double stub end having a first end secured to the inner race of the power input bearing and a second end protruding from the power input end of the hollow tubular composite axle;   a power output constant velocity joint comprising a power output bearing, the power output bearing comprising an inner race and an outer race, the exterior of the outer race being secured to the inner wall of the hollow tubular composite axle at the power output end; and   a power output double stub end having a first end secured to the inner race of the power output bearing and a second end protruding from the power output end of the hollow tubular axle.   
     
     
         8 . The composite half shalt of  claim 7  further comprising a flexible rubber boot, the rubber boot being attached at a first end around the power input end of the tubular composite axle or constant velocity joint and at the second end around the power input double stub end. 
     
     
         9 . The composite half shaft of  claim 7  wherein at least one of the power input constant velocity joint or power output constant velocity joint is press fit into the inner wall of the hollow tubular composite axle. 
     
     
         10 . The composite half shaft of  claim 7  wherein at least one of the power input constant velocity joint or the power output constant velocity joint is secured to the inner wall of the hollow tubular composite axle with an adhesive. 
     
     
         11 . The composite half shaft of  claim 7  wherein each of the power input constant velocity joint and the power output constant velocity joints are situated within the inner wall of the hollow tubular composite axle. 
     
     
         12 . The composite half shaft of  claim 7  wherein the constant velocity joint is a tripod joint.